Machine for forming and feeding coupons



July 15, 195s W. H. HARLAN MACHINE FOR FORMING AND FEEDING COUPONS 4Sheets-Sheet 1 Filed Aug. 28, 1953 IN1/Imran. (EN /lf d1un/4 ATTORNEYS.

July 15, 1958 w. H. HARLAN 2,842,911

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iinited States aten-t AVV MACHHNE FOR FRMNG AND FEEDING CUFNS Warren H.Harlan, Greenhilis, Ohio, assigner to The Procter & Gamble Company,Cincinnati, hio, a corporation oi @hin Application August Z3, i953,Serial No. 377,1@`

12 Qlaims. (Cl. ESQ-S7) My invention relates to means for forming andfeeding coupons, two-page leaflets, or other types oi' merchandisingliterature into packages, cartons or other containers which are iilledon high speed packaging machinery. The coupons7 or the like, may beformed from paper or other suitable sheet material. For the purpose ofsimplifying the following description, the papers or other articles tobe inserted will be referred to as coupons, and the packages into whichthey are to be inserted will be referred to as cartons, it beingunderstood that neither of these terms is to be taken in a limitingsense.

The coupons will ordinarily be inserted into cartons which containgranules, powders or material. in ake form, for example, soaps, otherdetergents, starch, breakfast foods, cake mixes, and the like. Thesematerials are conventionally packaged on high speed packaging machinerywhich sets up the cartons, closes one end of them, fills them withameasured or weighed quantity of the contents, and then closes and sealsthe opposite end. Devices have previously been suggested for insertingcoupons into cartons, but so far as i am aware these have beensuccessful in operation only up to a speed of Vabout 120 cartons perminute. Modern high speed packaging machinery, however, lls cartons upto 270 per minute consistently, and up to 300 per minute for short runs.

A principle object of this invention is the` provision of means forforming and feeding coupons accurately, and at such speeds as to beconsonant with the packaging speeds of modern packaging machinery asjust outlined. it is an object of 'my invention to provide a mechanismwhich will form and feed, or insert coupons at speeds which areadjustableV to the. speeds of they packaging machinery.

It is an object of my invention to provide a mechanism which will insurethe presenceoi'a coupon in each package or cartonof the productbeing'handled, and which Will operate to stop, the packaging mechanismif, forV any reason, the supply of coupons fails.

These and other objects of my invention which will be set forthhereinafter, or will be apparent to one skilled in the art upon readingthese specifications, l accomplish by that organizationA and assembly ofparts andbythat method of operation of which ishall now describe anexemplary embodiment. Reference. is made to the accompanying drawingswherein:

Figure l is a topplan View of my apparatus forfforming and feedingcoupons. p

Figure 2 is an -elevational'view thereof. Y

Figure 3 is'- a' partial sectional viewtaken alongfthe section line'-"lof Figure-2.

Figure 4' is a partial sectional View taken along'ithe section lined-tofFigureZ. p

Figurev 5"isapartial sectional view taken along the seetion'line 5 5 ofFigure 4.

Figure 6 is av partialsectionalfview ofthe cut-'ofi mechanism-takenalong the section line 6-6 of Figure 5.

Zii i Patented July 15, 1958 Figure 7 is a transverse sectional `viewrelated toV Figure 6, and taken along the section line 7-7 of thatfigure.

Figure 8 is a partial sectional view of a rapid feeding or insertionmechanism taken along the section line S- of Figure 5.

Figure 9 is an elevational view of the mechanism illustrated in sectionin Figure 8. y

Figure 10 is a plan View of the actuating finger of the mechanism ofFigure 9.

Figure 1l is a partial elevational view of the bearing mechanism for'the larger feeding roll.

Figure 12 is a partial plan view of the main clutch and clutch actuatingmechanism.

Figure 13 is a partial sectional View taken through the clutch andattendant partsalong thetsection line. 13--13 of Figure 12.

Figure 14 is a partial sectional view takenalong the section line 14-14of Figure l2.

Figure 15 is a perspective View of a completed coupon in the Vform inwhich it is inserted into the carton.

Figure 16 is a partial sectional view through the roll supply andmandrel showing means effective to stopV the mechanism ifV the supply ofcoupon material fails.

Referring first to Figures l andvZ which show the generalV layout of mycoupon forming and inserting mechanism, the index numeral 1 indicatesthe frame of a packaging machine which may be of any suitable type, andneed. not here be described. At the` point of use of myk couponmechanism, the packaging machine presents a series of cartons 5, 5a,etc., moving along in filled or unlled` but unclosed condition on aconveyor 5 which forms a part of the packaging machine. The open,upwardly extending tops or bottoms of the cartons are indicated at lil,10a. My coupon forming and inserting mechanism comprises a frame 11adapted to be attached'to the frame 1 of 'the packaging machine. in theframe i1 there is journaled aV shaft i2, bearing at one end an expansblemandrel 15 to accept a roll of preprinted coupon stock. Such a roll ofstock is indicated at 16. The expansible mandrel may be operated by ahandle element i7 to permit the installation of the roll. The oppositeend of'the shaft 12, on the other side of the frame 11, is fitted with asuitable tension brake such as one comprising a brake drum 1S and abrake band. Since the roll 16 is afxed toV 19 which is adjustable. theshaft through the expansible mandrel, it will be evident that thetension on the strip of coupon material 2t). being withdrawn from theroll can be set at any value desired.

The strip,k Zii'passes first over an idler 2li on an arm ZZand'nextoveran idler 23 on an arm 24. Between the idler sheaves 21 and 23, an idlerroll or sheave 25 on an, arm 26 rests by gravity on the strip. The arm2d is fastened by means of'a clamps` i to a shaft Edicurnaled on theframe. The opposite end of this shaft carries a lever 29 upon which acounterweight 3d is adjustably mounted for` the purpose of regulatingthe pressure of the idler 25 against the. strip.

it is desirable to provide a meansfor stopping the entirerriechanism,includingtheV packaging machine ifvthe supplyofcouponmaterial runs out or Vfails atthe roll 16. To this end a `limit switch31 is mountedv on bracket; 32 on the frame 11; As. shown in Figure 16,there' is a plateV .il-fi? mounted'on a sleeve 143 ar'iixed to theshaft'i2; The expansible mandrel 15`ts over thel sleeve; and the roll ofcoupon-forming material lies against'the'platc. The plate is perforated'as vat 149and is provided with a bracket' 59 on'which a spring pressednger ispivoted as shown. arranged to contact the roll of'coupon-forming`material,

One'end ofthis linger is.

whereby the finger is held in the position shown against the tension ofthe spring. When the supply of couponforming material is exhausted, thefinger swings in a counterclockwise direction in Figure 16, the otherend Vof the finger coming into position to contact and actuate thetrigger of the limit switch 31. YThe limit switch 31 will be effectivelyin the circuit of the main motor of the packaging machine, and thearrangement is such that if the supply of coupon material fails at thesource, the motor will be deenergized.

The strip 26 next passes beneath an idler 33 on a bracket 34 mounted onthe frame, and next over arlarge timing wheel 35, which will presentlybe described in detail. Y

The strip is provided with perforations or notches accurately related tothe printing on the strip. The timing wheel 35 is provided withV sets ofpins 36 for engaging in the perforations or notches. This enables thetiming wheel to maintain a xed relationship with the strip 20 and theprinted material thereon, so as to feed the strip in exact timedrelationship to cutting means later set forth.

I find it convenient to provide a splicing station in the space betweenidlers 23 and 33 as illustrated in Figure 2. This splicing stationconsists of a platform 37 held by a bracket 38 to the frame 11. Theplatform bears spaced pins 39 properly related to the spacing of theholes or notches in the strip. Thus, it becomes possible to locate thetrailing end of a supply of the strip material on the platform 37 bymeans of the pins, and then locate with respect to it the leading end ofa fresh supply of strip material in the same fashion, interposing asuitable adhesive between the lapping ends. By splicing a fresh supplyof the strip material to the end of a preceding supply, it becomespossible to operate the machine without rethreading.

The circumference of the timing wheel 35 is accurately proportioned tothe length of the printed coupons in the strip material 20. Preferablythe size of the wheel 35 is such that it can accept a plurality ofcoupon lengths about its circumference. In the illustrated embodimentthe wheel 35 has six sets of the pins 36, its circumference, thereforebeing equivalent to six coupon lengths.

The manner in which the timing wheel 35 is driven will be bestappreciated from the showing of Figure 3. Here a main drive shaft 40 isjournaled at one end in a prolongation of the frame 11 and, near itsother end, in a supplementary frame element 41. Beyond thissupplementary frame element, the main drive shaft 40 bears a sprocketand is connected by a chain 42 to a sprocket (not shown) aixed to themain drive of the packaging machine. Other drives, e. g. shafts andgears, may be employed to connect my coupon forming an inserting devicewith the drive of the packaging machine; but it is essential that thetwo mechanisms be connected together in such a way that the couponforming and inserting mechanism will be driven in exact timedrelationship with the packaging machine.

Between the housing or frame elements 11 and 41 the main drive shaft 40bears a clutch plate 43 having a notch 44. ln the illustrated embodimentthis clutch plate at one end, and a collar 45 at the other end serve tox the longitudinal position of the main drive shaft. R0- tatably mountedon the shaft 40 there is a wide gear element 46 carrying a Vsingledetent 47 adapted to enter the notch 44 of the clutch plate. The gear 46has an integral sleeve 43 which is connected by means of a ball bearingto a clutch operating ring 50. It will be evident fromthis constructionthat the gear 46 may be moved toward and away from the clutch plate 43byA means of the operating ring 50 so as to bring the detent into andout of engagement with the notch.

An adjacent shaft 51, again journaled in the frame Cir elements 11 and41, carries an element 52 non-rotatably affixed to it, as by means of akey or a set screw 53. This element has a sleeve portion 52a on which agear 54 is rotatably mounted. The upper face of this gear (as it isshown in Figure 3) has certain ball-receiving depressions 55 formedtherein. One or several balls 56 are mounted in bores 57 in the element52, and are urged toward the gear 54 by means of springs 58. When one ormore of the balls engage the depressions in the gear 54, the gear iscapable of rotating the element 52 and consequently the shaft 51 so asto transmit adequate power thereto. But the gear 54 and element 52,taken together, form a typel of clutch which will slip under suflicientresistance, and which will reengage for the transmission of power onlyin certain pre-arranged positions, as will be evident.

The sleeve 52a carries a gear 59 atiixed to it. This gear meshes with avery much larger gear 6i) on a shaft 61, journaled in the frame 11. Thetiming wheel 35 is mounted on the shaft 61 as shown.

In threading my mechanism it will be convenient to pass the strip ofcoupon material over and under the idlers heretofore described andengage it with the timing wheel 35. Thereafter the timing wheel may berotated to feed the strip further for threading purposes. To this end Iprefer to provide the shaft 61 of the timing wheel with a hand wheel 62,as shown in Figures i and 2.

The manner in which the main clutch of my apparatus is operated will bebest appreciated from Figures 12, 13 and 14. A shaft 63 is journaled inears on the frame member 41. A clutch operating lever 64 is aflixed tothis shaft. Also affixed to the shaft are a pair of arms 65 and 66,arranged to lie at opposite sides of the clutch operating ring 50. Thisring is provided with a pair of studs 67 and 68. The arms 65 and 66 arenotched to engage these studs. Springs 69 and 7) urge the clutchoperating ring 50 to clutch-closing position. It will be evident thatwhen the lower end of the clutch operating lever 64 is moved to theright in Figure l2 the clutch will be positively disengaged. When thelever is moved in the opposite direction, the clutch operating ring 5)will be released; but the clutch will not actually engage until thatposition is reached in which the detent 47 can enter the notch 44.

I aix a block 71 to the clutch operating lever 64. This block moves overa plate 72 (see Figure 14) aixed to the frame 11. The plate is providedwith recesses indicated at 73 and 74; and a spring pressed plunger 75having a nose adapted to enter either of these recesses is mounted in abore in the block 71. Thus, the clutch operating lever is provided witha definite clutch-open and clutch-closed position. One end of the spring69 may be attached to a pin 76 on the block 71 or to a pin on the frame11. By locating a limit switch 77 in the position shown in Figures 1, 2and 12, arrangement can be made so that this switch will =be actuatedwhen the clutch operating lever 64 is in the clutch-open positioru If,then, the'switch is arranged to be open circuited when the clutch leveris in the clutch-open position, and if the switch is effectively locatedin the circuit of the main motor of the packaging machine, it will beevident that the packaging machine cannot operate so long as the couponforming and inserting mechanism is not operating.

Tracing the path of the coupon strip 20 as it leaves the timing wheel 35(this is most conveniently done in Figure 2) it will be seen that thestrip passes over an idler 78 on an arm 79 aixed to the frame 11, andthen under a folding wheel or disc 80 on an arm 81, and into a pair ofpinch rolls one of which is shown at 82. These pinch rolls feed the nowdoubled or folded strip to a cutting mechanism located beneath theplatform or bracket 83 in Figure 2, where the folded strip is severedinto individual coupons. assures the timing of the strip as fed, it isadvantageous Since the timing wheel hereinabove describedto drive thepinch roll at a speed slightly faster than the speed of the strip so asto maintain tension thereon. As soon as a coupon has thus been severedfrom the strip, it is engaged by a rapidly operating pair of feed rolls,one of which is shown at 84, and is projected yat a substantially higherrate of speed into the open end of the carton 5.

The form, mounting, and drives for this mechanism will best beappreciated by considering Figures 3'to 7 inclusive. A supplementaryframe member or bracket 85 is aihxed to the frame 11 at rightanglesthereto. An assembly consisting of a bevel gear 87, a relatively largegear 33, and a relatively small gear 89 is journaled by means of ballbearings on a stub shafttl (see VFigure 52). This assembly is driven bya bevel gear 86 .on the end of the shaft 51 (Figure 3) which meshes withthe bevel gear 87.

The smaller gear 89 meshes with a gear 91 on a shaft 92. The gear 91 inturn meshes with a gear 93.]ournaled on a stub shaft 94. The gear 93meshes with a gear 95 on a shaft 96. This shaft'is journaled in theframe member 85, and on its opposite end bears the roll 82 of the pinchroll combination mentioned above. The mating roll of this pinch rollcombination is not illustrated in any of the iigures, but it will beunderstood as being a roll mounted on a shaft 97, bearing'a gear 98`meshing with the gear 95. The shaft 97 is not journaled directly in'the bracket or frame member 85 but instead is journaled in a block 99which is pivoted tothe frame member as at ldd in Figure 4. Anoperatinghandle 101 is aixed to this block, and is connected byaspring'102 to a stud 1113 on the frame 11. The spring insures that theupper and lower pinch rolls will be pressed together under sufcientforce for positive, timed feeding; but 'by operating the handle 101 therolls may berdrawn apart for threading purposes.

The pinch roll combination feeds the `folded strip to a severing meansnext to be described. The shaft 92 is journaled at one end in a ballbearing 11M in the frame member 85, and at the other end .in aballbearing 105 in the angularly related end 83aof thesupplementary framemember or platform 83. Theshaft 92 carries fa roll 106 to which aily-knife 107 is aixed. In order to obviate any lost motion,misalignment, or change of position of the shaft 92, it is provided withVa pair of extra `ball bearings 108 and 1%19.Ringsfsurrounding'theserbearings (as most clearly shown in Figure 6) areprovided with headed studs 110 and 11'1 which, passingthrough holes inthe frame member 11, are Vresili'ently urged in o-ne direction bysprings 112 and 113 engagedbetween the frame member and `theirrespective heads. It may be noted that the forces generated by gears 89and V931 meshing with gear 91 also tend to move gear 91 and its shaft 92in the direction of the urge of the springs 112 and 113.

The fly-knife 107 Von the 'roll 106 coacts witha stationary knife `11d(Figure 7) affixed to a ,block 115 which is slidable'on the members83and 85 and is aixed thereto by bolts 116 and 117 Voperating in oval orlaterally elongated holes in the members 85 and 83. The position of theblock 115 can be very accurately adjusted by means of set screws 118 and119, and the block then rmly fastened in position by means of the bolts.Thus, the stationary knife 114 can be made to coact properly with theily-knife 107. It will be understood that the gearing arrangement causesthe knife to cut the strip, which is being fed to it in timedrelationship, in such manner as to sever each coupon from the nextsucceeding one. Ordinarily the mechanism is timed so that the cuts aremade at the positions of the holes or notches in the strip, giving thefolded coupon in the form illustrated at 120 in Figure l5.

There remains the mechanism for feeding the severed coupons into thecartons as they move along the conveyor 9. Referring again to Figure 4,it will be seen that the 6 gear 88 meshes with a gear 121 on a shaft122. This shaft is` journaled, as lshown in Figure 5, in the bracket orframe element 85, and bears on its outer end a feed roll 123. This feedVroll is grooved centrally as at 123a for a purpose vhereinafterdescribed.

The shaft 122 kalso bears a gear 124 whichmeshes with a vgear 125 on ashaft 12'6. The shaft 126 on its outer endcarries afsomewhat thinnerroller but of larger diameter, 127 (see Figures 8 and 9). This roller isalso grooved as at 128.

The shaft 126 is not journaled in the frame element 85, but rather in ablock 129 which is pivoted to the member S5 as at 130. The block 129bears a stud 131 which is connected by a spring 132 to another stud 133on 'the frame element 85 as shown in Figure 4. The purpose of thisconstruction is to permit a very iine adjustment of therelativepositions of the shafts 122 and 126. To this end, the block 129 may beprovided with a set screw adjusting means 134 adapted to engage againstthe member '85. A supplementary flocking screw 135 maybe pro vided ifdesired (Figure ll).

A lever 136, shaped as shown best in Figure l0, is pivotedas at -13'7soasto -lie partly within the groove of the roll 127. This-leverhaspins138 and 'operating through slots 140 and 141 in one of the cheeks of theroller 127 (see Figure 9). The pin 138 is connected by a spring 142 toalpin 145 on the roller 127 in such fashion as to urge the lever yto theposition shown in Figure 9, in which the lower end of the lever projectsbeyond the periphery of thevroll 127. The pin 139 on the lever projectsfar enough beyond the face of the roller 127 to engage the operating arm144 of a limit switch 145 on a bracket 146.'

The roller 123 is grooved as at 123e to permit the lever 136 to assumethe -position shown in Figure 9.

The roller 127 is provided with a pad 146 of such circumferential lengthand thickness as to coact with the roller 123 in feeding-a severedcoupon. The adjustment of the positions of the shafts 122 and 126 issuch that a coupon will not be ygripped'between the rollers 123 and 127excepting when the pad 146 also lies in the bite between these tworollers. But it will now also be evident that if a coupon is engagedbetween the roller 123 and the pad 146 onftheroller 127, the `lever 136cannot assume the position shown in Figure 9; instead, its outer endwill be depressedwithinthe groove `of the roller 127", and its other endwillztbefraised within the notch 141. This brings thepin 139out ofposition to actuate the lever 14d of the limit switch V145.opencircuited .whentactuated and is located effectively in the circuitof themainmotor of the-packaging machine, it will be evident that theVmotor may run so long as severed .coupons .aresuccessively and properlyfed by the rolls 123 and 127.` Shouldiacoupon fail 'to be engagedbetween these rollersat thelproper time, however, thc

switch will be actuated, andthe entire mechanism will be stopped. v

The rollers 123,:and 127 are timed .so as to feed the coupons at a verymuch greater rate/of speed than the speed of travel of the coupon stripbefore severance. Consequently the introduction or insertion of thesevered coupons into the cartons 5, 5a, etc. is extremely rapid andpositive. The cartons, passing on from the position shown in Figure 2,are lled and/ or closed and sealed, by the standard mechanism of thepackaging machine.

Modifications may be made in my invention without departing from thespirit of it. Having thus described may invention in an exemplaryembodiment, what I claim as new and desire to secure by Letters Patentis:

1. In a machine for forming and feeding coupons into cartons, theimprovement which comprises in combination a feeding mandrel withconstant tension braking means, said mandrel adapted to hold a supply ofcoupon-forming material in rolled strip form, said strip beingperforated or notched in index with printing thereon, a timing roll Ifthis switch is arranged to be having projections to engage the holes ornotches'in the strip, pinch rolls adapted to feed the strip bywithdrawing it from the timing roll, a cut-off knife adapted to cut thestrip into separate coupons while said strip is moving, a pair ofimpelling rolls to grip the severed coupons and feed them into cartons,means for continuously driving said timing roll, pinch rolls, cut-offknife and impelling rolls in timed relationship with each other, saidmeans adapted to synchronize the relative motion of said timing roll tosaid cut-off knife so that said coupons are cut from said strip in indexwith the printing thereon.

2. Apparatus -claimed in claim 1 including folding means operativebetween the said timing roll and the said cut-oif knife.

3. In a machine of the character described, in sequence, means forsupplying coupon material in the form of a lstrip of indenite length,said strip having perforations or notches registering with printingthereon, a timing wheel having projections to engage in saidperfcrations or notches, a pair of pinch rolls, and a rotary cut-offknife, said cut-off knife adapted to cut said strip in registry with theprinting thereon while said strip is moving, continuous means fordriving said timing wheel, pinch rolls and cuto knife in timedrelationship, and means permitting the rotation of said timing wheel forthreading purposes, said means comprising a dsengageable clutch in thedrive of said timing roll, said clutch having predetermined positions ofengagement such that said coupon material will at all times be fed inregistry to said cut-off knife when said timing roll and said cut-offknife are being driven.

4. Apparatus claimed in claim 3 including folding means located betweensaid timing roll and said pinch rolls.

5. Apparatus claimed in claim 4 including a pair of impelling rollsadapted to receive severed coupons from said cut-oi knife and deliverthem at a linear speed in excess of the speed of travel of said strip,and driving means for said impelling rolls.

6. In a packaging machine in which unclosed cartons are moved at a rateof about 270 a minute or more in sequence past a point, a continuouslyrevolving drive and motor for said packaging machine, an apparatus forforming and feeding coupons into said cartons, said apparatus beinglocated at said point and comprising a supply of coupon material instrip form, said strip having perforations or notches registering withprinting thereon, a timing roll having projections for entering saidperforations or notches, a pair of feeding rolls, a rotary cut-off knifeand a pair of impelling rolls for receiving coupons severed from saidstrip by said cutot knife and impelling them at enhanced speed into saidcartons, drive mechanism for said timing roll, said pinch rolls, saidcut-01T knife and said impelling rolls, and aV timed connection betweensaid drive mechanism and the said drive for said packaging machine.

7. Apparatus claimed in claim 6 including means whereby said timing rollmay be rotated for threading purposes without detiming the timedmechanism, said means comprising a dsengageable clutch connected to saidtiming roll, said clutch being engageable only in predetermined timedpositions.

'8. Apparatus claimed in claim 6 including means whereby said timingroll may be rotated for threading purposes without detiming the timedmechanism, said means comprising a dsengageable clutch connected to saidtiming roll, said clutch being engageable only in predetermined timedpositions, and a hand wheel connected to said timing roll.

9. The structure claimed in claim 8 in which a clutch is interposedbetween said driving mechanism and the drive for said packaging machine,said clutch having an operating lever, a limit switch in the circuit ofsaid motor and means for actuating said switch when said last mentionedclutch is open whereby to deenergize said motor.

10. The structure claimed in claim 9 in which one of said impellingrolls carries a coupon-actuated nger, a limit switch arranged to beactuated by said finger upon operation of said impelling rolls in theabsence of a coupon, said limit switch being located in the circuit ofsaid motor whereby to stop said packaging machine and the coupon formingand feeding machine in the event of coupon failure.

l1. Apparatus claimed in claim 10 including a means contacting saidsupply of coupon material, and a third limit switch located in thecircuit of said motor and adapted to be actuated by said contactingmeans whereby the packaging machine and coupon forming and feedingmachine will be stopped in the event of strip failure.

12. In a coupon forming and feeding device, a pair of slotted impellingrolls, a linger pivoted in the slot of one roll and having an endadapted to enter the slot of the other roll under the inuence of abiasing spring, a limit switch having an actuating member, a pin on theother end of said finger for striking said actuating member when saidfinger is in the aforesaid position, the arrangement being such that thepresence of a coupon between said rolls will move the end of said leverout of the slot in said second mentioned roll, and said pin into aposition in which it cannot contact said actuating member.

References Cited in the le of this patent UNITED STATES PATENTS1,247,364 Bracy Nov. 20, 1917 2,100,776 Fulk Nov. 30, 1937 2,109,505 RueMar. 1, 1938 2,208,345 Rosebush July 16, 1940 2,361,421 Sherman Oct. 31,1944 2,456,449 Rouan Dec. 14, 1948 2,470,557 Herrmann May 17, 19492,518,011 Hoppe Aug. 8, 1950 2,521,435 Wockenfuss Sept. 5, 19502,586,055 Kanick Feb. 19, 1952 2,632,545 Schubert Mar. 24, 1953

